Grouting theories and technologies for the reinforcement of fractured rocks surrounding deep roadways

Grouting is an effective method to improve the integrity and stability of fractured rocks that surround deep roadways.After years of research and practice,various theories and a complete set of grouting technologies for deep roadways with fractured rocks have been developed and are widely applied in Chinese coal mining production.This paper systematically summarizes and analyzes the research results concerning the theory,design,materials,processes,and equipment for the grouting and reinforcement of fractured rocks surrounding deep roadways.Specifically,in terms of grouting methods,pregrouting,groutingwhile-excavation,and postgrouting methods are explored;in terms of grouting theory,backfill grouting,compaction grouting,infiltration grouting,and fracture grouting theories are studied.In addition,this paper also studies grouting borehole arrangement,water-cement ratio,grouting pressure,grouting volume,grout diffusion radius,and other grouting parameters and their determination methods.On this basis,this paper explores the physical and mechanical properties of organic and organic-inorganic composite grouting materials,and assess grouting reinforcement quality testing methods and instruments.Taken as the field cases,the application of pregrouting in front of heading faces,groutingwhile-excavation,and postgrouting in the Kouzidong coal mine are then introduced,and the effects of the grouting reinforcements are evaluated.This paper proposes a development direction for grouting technology based on problems existing in the grouting reinforcement of fractured rocks surrounding deep roadways.

Deformation and failure characteristics of anchorage structure of surrounding rock in deep roadway

This paper investigated the stress evolution,displacement field,local deformation and its overall distribution,and failure characteristics of the anchorage structure of surrounding rock with different rockbolt spacing through the model experiments.The influences of the pre-tightening force and spacing of rockbolt on the support strength of the anchorage structure of surrounding rock were analyzed by the simulation using FLAC3D numerical software.The support scheme of the excavated roadway was then designed,and the effectiveness of this support scheme was further verified by the displacement measurement of the roadway.The results showed that the maximum displacement between the roof and floor of the west wing track roadway in Kouzidong coal mine,China is about 42 mm,and the maximum displacement between its both sides is about 72 mm,indicating that the support scheme proposed in this study can ensure the stability and safety of the excavated roadway.

Support technology of deep roadway under high stress and its application

Roadway instability has been a major concern in the fields of mining engineering. This paper aims to provide practical and efficient strategy to support the roadways under high in-situ stress. A case study on the stability of deep roadways was carried out in an underground mine in Gansu province, China. Currently,the surrounding rock strata is extremely fractured, which results in a series of engineering disasters, such as side wall collapse and severe floor heave in the past decades. Aiming to solve these problems, an improved support method was proposed, which includes optimal bolt parameters and arrangement, floor beam layout by grooving, and full length grouting. Based on the modeling results by FLAC3D, the new support method is much better than the current one in terms of preventing the large deformation of surrounding rock and restricting the development of plastic zones. For implementation and verification, field experiments, along with deformation monitoring, were conducted in the 958 level roadway of Mining II areas. The results show that the improved support can significantly reduce surrounding rock deformation, avoid frequent repair, and maintain the long-term stability of the roadway. Compared to the original support, the new support method can greatly save investment of mines, and has good application value and popularization value.

Surrounding Rock Control Technology of Strong Dynamic Pressure Roadway in Hudi Coal Industry

Aiming at the problems of large deformation and difficult maintenance of deep soft rock roadway under the influence of high ground stress and strong dynamic pressure, taking the surrounding rock control of 1105 lane in Hudi Coal Industry as an example, the deformation characteristics and surrounding rock control measures of deep soft rock roadway are analyzed and discussed by means of geological data analysis, roadway deformation monitoring, rock crack drilling and field test. The results show that the main causes of roadway deformation are high ground stress, synclinal tectonic stress, advance mining stress, roadway penetration and surrounding rock fissure development. Based on the deformation characteristics and mechanism of lane 1105, the supporting countermeasures of “roof synergic support, layered grouting, anchor cable beam support, closed hardening of roadway surface” are proposed, which can provide reference for the control of deep roadway surrounding rock under similar conditions.

Comparison of large deformation failure control method in a deep gob-side roadway: A theoretical analysis and field investigation

Under the dual influence of the mining disturbance of the previous working face and the advanced mining of the working face,the roadway is prone to large deformation,failure,and rockburst.Roadway stabilization has always significantly influenced deep mining safety.In this article we used the research background of the large deformation failure roadway of Fa-er Coal Mine in Guizhou Province of China to propose two control methods:bolt-cable-mesh+concrete blocks+directional energy-gathering blasting(BCM-CBDE method)and 1st Generation-Negative Poisson’s Ratio(1G NPR)cable+directional energy-gathering blasting+dynamic pressure stage support(πgirder+single hydraulic prop+retractable U steel)(NPR-DEDP method).Meantime,we compared the validity of the large deformation failure control method in a deep gob-side roadway based on theoretical analysis,numerical simulations,and field experiments.The results show that directional energy-gathering blasting can weaken the pressure acting on the concrete blocks.However,the vertical stress of the surrounding rock of the roadway is still concentrated in the entity coal side and the concrete blocks,showing a’bimodal’distribution.BCM-CBDE method cannot effectively control the stability of the roadway.NPR-DEDP method removed the concrete blocks.It shows using the 1G NPR cable with periodic slipping-sticking characteristics can adapt to repeated mining disturbances.The peak value of the vertical stress of the roadway is reduced and transferred to the deep part of the surrounding rock mass,which promotes the collapse of the gangue in the goaf and fills the goaf.The pressure of the roadway roof is reduced,and the gob-side roadway is fundamentally protected.Meantime,the dynamic pressure stage support method withπgirder+single hydraulic prop+retractable U steel as the core effectively protects the roadway from dynamic pressure impact when the main roof is periodically broken.After the on-site implementation of NPR-DEDP method,the deformation of the roadway is reduced by more than 45%,and the deformation rate is reduced by more than 50%.

Support technologies for deep and complex roadways in underground coal mines:a review

Based on geological and mining characteristics,coal mine roadways under complex conditions were divided into five types,for each type the deformation and damage characteristics of rocks surrounding roadways were analyzed.The recent developments of roadway support technologies were introduced abroad,based on the experiences of supports for deep and complex roadways from Germany,the United States and Australia.The history and achievements of roadway support technologies in China were detailed,including rock bolting,steel supports,grouting reinforcement and combined supports.Four typical support and reinforcement case studies were analyzed,including a high stressed roadway 1,000 m below the surface,a roadway surrounded by severely weak and broken rocks,a chamber surrounded by weak and broken rocks,and a roadway with very soft and swelling rocks.Based on studies and practices in many years,rock bolting has become the mainstream roadway support form in China coal mines,and steel supports,grouting reinforcement and combined supports have also been applied at proper occasions,which have provided reliable technical measures for the safe and high effective construction and mining of underground coal mines.

Bolt-grouting combined support technology in deep soft rock roadway

Analyzing the mineral composition, mechanical properties and ground stress testing in surrounding rock,the study investigated the failure mechanism of deep soft rock roadway with high stress. The boltgrouting combined support system was proposed to prevent such failures. By means of FLAC3D numerical simulation and similar material simulation, the feasibility of the support design and the effectiveness of support parameters were discussed. According to the monitoring the surface and deep displacement in surrounding rock as well as bolt axial load, this paper analyzed the deformation of surrounding rock and the stress condition of the support structure. The monitor results were used to optimize the proposed support scheme. The results of field monitors demonstrate that the bolt-grouting combined support technology could improve the surround rock strength and bearing capacity of support structure, which controlled the great deformation failure and rheological property effectively in deep soft rock roadway with high stress. As a result, the long term stability and safety are guaranteed.

Influence of dynamic pressure on deep underground soft rock roadway support and its application

Due to high ground stress and mining disturbance, the deformation and failure of deep soft rock roadway is serious, and invalidation of the anchor net-anchor cable supporting structure occurs. The failure characteristics of roadways revealed with the help of the ground pressure monitoring. Theoretical analysis was adopted to analyze the influence of mining disturbance on stress distribution in surrounding rock,and the change of stress was also calculated. Considering the change of stress in surrounding rock of bottom extraction roadway, the displacement, plastic zone and distribution law of principal stress difference under different support schemes were studied by means of FLAC3D. The supporting scheme of U-shaped steel was proposed for bottom extraction roadway that underwent mining disturbance. We carried out a similarity model test to verify the effect of support in dynamic pressure. Monitoring results demonstrated the change rules of deformation and stress of surrounding rock in different supporting schemes. The supporting scheme of U-shaped steel had an effective control on deformation of surrounding rock. The scheme was successfully applied in underground engineering practice, and achieved good technical and economic benefits.

Research on Robotized Advance Support and Supporting Time for Deep Fully Mechanized Excavation Roadway

To keep coal workers away from the hazardous area with frequent accidents such as the roof fall and rib spalling in an underground coalmine,we put forward the solution with robotized self-moving anchor-supporting unit.The existing research shows that the surrounding rock of the roadway has self-stability,and the early or late support is not conducive to the safe and reliable support of the roadway,so there is a problem of support opportunity.In order to study the supporting effect and the optimal supporting time of the above solution,we established the mechanical coupling model of surrounding rock and advance support,and investigated the surrounding rock deformation and advance support pressure distribution under different reserved roof subsidence by using the numerical simulation software FLAC3D.The results show that the deformation of surrounding rock increases and finally tends to a stable level with the increase of pre settlement of roadway roof,and when the pre settlement of roof is between 8-15 mm,the vertical pressure of the top beam of advance support reaches the minimum value,about 0.58 MPa.Based on the above research,we put forward the optimum supporting time in roadway excavation,and summarized the evaluation method based on the mechanical coupling model of surrounding rock-advance support.

Failure mechanism and control technology of deep soft-rock roadways:Numerical simulation and field study

Large deformations such as roof subsidence,floor heave,and two-sided deformations occur frequently in deep soft-rock roadways.The deformation becomes more severe under the combined effect of high in-situ and mining-induced stresses,which detrimentally affect the safe mining of coal.Based on the geological conditions and roadway failure characteristics of the Nanyaotou coal mine in Shanxi province,China,we used comprehensive numerical simulations and field observations to study roadway deformation and failure.The deformation mechanism of deep soft-rock roadways under dynamic pressures is described,and the corresponding control measures are proposed.The deformation and fracture development characteristics of roadways surrounding rocks were explored with a primary support scheme,and its effects were evaluated.The radius of the plastic zone and the displacement deformation of the roadway were studied by using theoretical analysis,and a combined-support design of‘‘anchor bolt+anchor cable+shotcrete+deep and shallow borehole grouting+inverted arch”was proposed to limit deformations and relieve the stress in the surrounding rocks.Numerical simulations and field monitoring showed that the combined support scheme can effectively mitigate the large deformations of ventilation roadways and provide guidance for the stable control of deep soft-rock roadways.